Trinity Highway QuadGuard II Assembly Manual

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QuadGuard® II

The QuadGuard® II has been tested pursuant to National Cooperative Highway Research Program (“NCHRP”) Report 350 specifications. The QuadGuard reimbursement on the National Highway System by the Federal Highway Administration (“FHWA”).

II has been deemed eligible for federal-aid

Assembly Manual

2525 N. Stemmons Freeway

Dallas, Texas 75207

Warning:

lessors, and lessees are RESPONSIBLE for the assembly, maintenance, and repair of the QuadGuard respect to the assembly, maintenance, and repair of the QuadGuard system could result in serious injury or death.

The local highway authority, distributors, owners, contractors,

II. Failure to fulfill these RESPONSIBILITIES with

Important:

appropriate highway authority. In the event the specified system assembly, maintenance, or repair would require a deviation from standard assembly parameters, contact a Trinity Highway representative. This system has been deemed eligible by the FHWA for use on the national highway system under strict criteria utilized by that agency.

This manual must be available to the worker overseeing and/or assembling the product at all times. For additional copies, contact Trinity Highway directly at (888) 323-6374 or visit

trinityhighway.com.

The instructions contained in this manual supersede all previous information and manuals. All information, illustrations, and specifications in this manual are based on the latest QuadGuard information available to Trinity Highway at the time of printing. We reserve the right to make changes at any time. Please contact Trinity Highway to confirm that you are referring to the most current instructions.

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These instructions are for standard assembly specified by the

Part No. 115270

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Table of Contents

Customer Service Contacts .......................................................................................................... 3

Important Introductory Notes ........................................................................................................ 3

Safety Symbols ............................................................................................................................. 4

Safety Rules for Assembly ............................................................................................................ 4

Limitations and Warnings .............................................................................................................. 5

System Overview .......................................................................................................................... 6

Inspect Shipping...................................................................................................................... 6

System Components ............................................................................................................... 7

Foundation/Anchoring ................................................................................................................. 12

Recommended Tools .................................................................................................................. 13

Site Preparation/Foundation ....................................................................................................... 15

Trinity Highway Approved Adhesive Anchoring System ............................................................. 16

Vertical Assemblies ............................................................................................................... 16

Anchor Assembly Cautions ................................................................................................... 17

Horizontal Assemblies ........................................................................................................... 18

How to Determine Left/Right ................................................................................................. 20

Counting the Number of Bays ............................................................................................... 20

Parallel (Narrow) Systems .......................................................................................................... 22

Assemble Parallel (Narrow) ........................................................................................................ 23

Determine Backup and Transition Type ................................................................................ 23

Flared (Wide) Systems ............................................................................................................... 40

Assemble Flared (Wide) ............................................................................................................. 41

Determine Backup and Transition Type ................................................................................ 41

QuadGuard

Maintenance and Repair ............................................................................................................. 58

Inspection Frequency ............................................................................................................ 58

Visual Drive-By Inspection .................................................................................................... 58

Walk-Up Checklist ................................................................................................................. 58

Post-Impact Instructions ........................................................................................................ 59

Parts Ordering Procedure ........................................................................................................... 62

II Final Inspection Checklist ................................................................................... 57

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Customer Service Contacts

Trinity Highway is committed to the highest level of customer service. Feedback regarding the QuadGuard

II, its assembly procedures, supporting documentation, and performance is always

welcome. Additional information can be obtained from the contact information below:

Trinity Highway

Telephone:

E-mail: [email protected]

Website: trinityhighway.com

(888) 323-6374 (USA) +1 214 589-8140 (International)

Important Introductory Notes

The performance of the QuadGuard® II as designed, and approved for reimbursement by the FHWA pursuant to its NCHRP Report 350 standard, is dependent upon the proper assembly, deployment and future maintenance of the system. These instructions must be read in their entirety and understood before assembling the QuadGuard in conjunction with the assembly of QuadGuard

II and are for standard assemblies only as specified by the applicable highway authority. If you need additional information, or have questions about the QuadGuard

II, please contact the highway authority that has planned and specified this assembly and, if needed, contact Trinity Highway Customer Service. This product must be assembled in the location specified by the appropriate highway authority. If there are deviations, alterations, or departures from the assembly instructions specified in this manual, the device may not perform as tested.

II. These instructions are to be used

Important:

specified herein for the QuadGuard

DO NOT use any component part that has not been specifically

II during the assembly or repair (pp. 7 – 11 /

63 - 64).

This product has been specified for use by the appropriate highway authority and has been provided to that user who has unique knowledge of how this system is to be assembled. No person should be permitted to assemble, maintain, or repair this system that does not possess the unique knowledge described herein. These instructions are intended for an individual qualified to both read and accurately interpret them as written. These instructions are intended only for an individual experienced and skilled in the assembly of highway products that are specified and selected by the highway authority.

A manufacturer’s drawing package will be supplied by Trinity Highway upon request. Each system will be supplied with a specific drawing package unique to that system. Such drawings take precedence over information in this manual and shall be studied thoroughly by a qualified individual who is skilled in interpreting them before the start of any product assembly.

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Safety Symbols

This section describes the safety symbols that appear in this manual. Read the manual for complete safety, assembly, operating, maintenance, repair, and service information.

Symbol Meaning

Safety Alert Symbol:

Indicates Important, Caution, Warning, or Danger. Failure to read and follow the Important, Caution, Warning, or Danger indicators could result in serious injury or death to the workers and/or bystanders.

Warning:

Read safety instructions thoroughly and follow the assembly directions and suggested safe practices before assembling, maintaining, or repairing the QuadGuard

II. It is the responsibility of the installer to follow these warnings. Failure to comply with these warnings could result in increased risk of serious injury or death in the event of a vehicle impact with a system.

Important:

Please keep up-to-date instructions for later use and reference by

anyone involved in the assembly of the product.

Safety Rules for Assembly

* Important Safety Instructions *

This manual must be kept in a location where it is readily available to per sons who are skilled and experienced in the assembly, maintenance, or repair of the QuadGuard this manual are available from Trinity Highway by calling (888) 323-6374, or by email at [email protected], or at trinityhighway.com. Please contact Trinity Highway if you have any questions concerning the information in this manual or about the QuadGuard® II.

It is the responsibility of the installer to use appropriate safety precautions when operating power equipment, mixing chemicals, and when moving heavy equipment or QuadGuard Safety articles including but not necessarily limited to work gloves, eye protection, safety-toe shoes, and back support should be used.

II. Additional copies of

II components.

Warning:

It is the responsibility of the installer to use all safety measures

incorporating appropriate traffic control devices specified by the highway authority. These measures must be used to protect all personnel while at the assembly, maintenance, or repair site.

Warning:

Failure to comply with these warnings could result in increased risk of serious injury or death in the event of a vehicle impact with a system that has not been accepted by the FHWA.

Warning:

Use only Trinity Highway parts on the QuadGuard® II for assembly,

maintenance, or repair. The use of component parts not specified herein is strictly

prohibited. The QuadGuard

tested, approved, and accepted for state use by the FHWA. A QuadGuard

II assembled with Trinity Highway parts has been

II using parts other than those specified herein has not been tested, approved, or accepted for state use by the FHWA. Failure to follow this warning could result in increased risk of serious injury or death in the event of a vehicle impact.

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Limitations and Warnings

Trinity Highway contracts with FHWA approved testing facilities to perform crash tests, evaluate test results, and submit results to the FHWA for review.

The QuadGuard requirements and guidelines of NCHRP Report 350. NCHRP Report 350 tests are designed to evaluate product performance involving a range of vehicles on roadways, from lightweight cars (approx. 1800 lb. [820 kg]) to full size pickup trucks (approx. 4400 lb. [2000 kg]). A product can be certified for multiple Test Levels. The QuadGuard shown below:

Test Level 2: 43 mph [70 km/h] Test Level 3: 62 mph [100 km/h]

These FHWA directed tests are not intended to represent the performance of systems when impacted by every vehicle type or every impact condition existing on the roadway. This system is tested only to the test matrix criteria of NCHRP Report 350 as approved by FHWA.

Trinity Highway expressly disclaims any warranty or liability for injury or damage to persons or property resulting from any impact, collision or harmful contact with products, other vehicles, or nearby

hazards or objects by any vehicle, object or person, whether or not the products were

assembled in consultation with Trinity Highway or by third parties. The QuadGuard

and federal guidelines. It is important for the highway authority specifying the use of a highway product to select the most appropriate product configuration for its site specifications. The customer should be careful to properly select, assemble, and maintain the product. Site lay out, vehicle population type; speed, traffic direction, and visibility are important elements that require evaluation in the selection of a highway product. For example, curbs could cause an untested effect on an impacting vehicle.

II has been deemed eligible for reimbursement by FHWA as meeting the

II system is certified to the Test Level(s) as

II is intended to be assembled, delineated, and maintained within specific state

After an impact occurs, the debris from the impact should be removed from the area immediately and the specified highway product should be evaluated and restored to its original specified condition or replaced as the highway authority determines as soon as possible.

Warning: Do not assemble, maintain, or repair the QuadGuard

II until you have read this manual thoroughly and completely understand it. Ensure that all Danger, Warning, Caution, and Important statements within the manual are completely followed. Please call Trinity Highway at (888) 323-6374 if you do not understand these instructions.

Warning: Ensure that all of the QuadGuard

Important statements within the QuadGuard

II Danger, Warning, Caution, and

II manual are completely followed. Failure to follow this warning could result in serious injury or death in the event of a collision.

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System Overview

The QuadGuard® II is a re-directive, non-gating crash cushion for roadside obstacles ranging in width from 24" to 126" (610 mm to 3200 mm). It consists of energy-absorbing cartridges surrounded by a framework of Quad-Beam Panels.

Important:

reuse of any part of the system is appropriate or acceptable following an impact. It is the sole responsibility of the project engineer and/or the local highway authority and its engineers to make that determination. It is critical that you inspect this product after assembly is complete to make certain that the instructions provided in this manual have been strictly followed.

The QuadGuard both lighter cars and heavier, high center-of-gravity vehicles. Its modular design allows the system length to be tailored to the design speed of a site.

II utilizes two types of cartridges in a staged configuration designed to address

Trinity Highway makes no recommendation whether use or

Impact Performance

The 5 Bay QuadGuard® II has successfully passed the requirements outlined in NCHRP Report 350, Test Level 3 tests with both the light car and pickup at speeds of up to 62 mph [1 00 km/h] at angles up to 20 degrees.

During head-on impact testing, within NCHRP Report 350 criteria, the QuadGuard® II is designed to telescope rearward to absorb the energy of impact. When impacted from the side, within the applicable NCHRP Report 350 criteria, it is designed to redirect the vehicle back toward its original travel path and away from the roadside obstacle.

Warning:

Do not modify the QuadGuard® II in any way.

Warning:

authority and its engineer to ensure that the QuadGuard meet all federal, state, specifying agency, and local specifications.

Warning:

authority and its engineer to ensure delineation on the assembly meets all appropriate Manual on Uniform Traffic Control Devices (“MUTCD”) and local standards.

It is the responsibility of the project engineer and / or local highway

II and delineation used

Inspect Shipping

Before deploying the QuadGuard® II, check the received parts against the shipping list supplied with the system. Make sure all parts have been received.

Important:

QuadGuard

should take precedence over these general instructions.

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The Manufacturer’s Drawing Package supplied with the

II must be used with these instructions for proper assembly and

Page 8

System Components

Below is a list of system components to be used in the repair of your particular QuadGuard® II configuration. Please call Trinity Highway customer support if you have any system questions (p. 3).

Warning:

QuadGuard

Use only Trinity Highway parts that are specified herein for the

II for assembling, maintaining, or repairing the QuadGuard® II. Do

not utilize or otherwise comingle parts from other systems even if those

systems are other Trinity Highway systems. Such configurations have not been

tested, nor have they been deemed eligible for use. Assembly, maintenance, or repairs using unspecified parts or accessories is strictly prohibited.

Note:

Components are not shown to scale.

Narrow Diaphragm Assemblies * Wide Diaphragm Assemblies *

607173 - 26.48”

625650 - 24” 625651 - 30” 625652 - 36” 606810 - 48”

607174 – 29.65” 607175 – 32.78” 607176 – 35.93” 607177 – 39.08” 607145 – 42.23” 607146 – 45.38”

607148 – 48.53” 607149 – 50.11” 607150 – 51.68” 607151 – 54.83” 607152 – 57.98” 607156 – 59.56”

607157 – 61.13” 607158 – 64.28” 607159 – 68.06” 607160 – 70.58” 607162 – 73.73” 607163 – 76.88” 607164 – 80.04”

Nose, Narrow Assembly * Nose, Narrow Assembly 48” * Nose, Wide Assembly *

611580 - Galvanized

611581 - Yellow

611579 - Black

611577 - Galvanized

611578 – Yellow

611576 - Black

611583 – Galvanized

611584 – Yellow

611582 - Black

* Assemblies include multiple parts.

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Mushroom Washer Flat Screw 5/8X8 1/2" Wide Die Spring, 6”, Wide

617045 116879 117458

Flat Screw 5/8X5”,G8, Narrow Die Spring, 1 1/2”, Narrow Rail Nut, Hex, 5/8”

116878 117459 003340

Rail Bolt, 5/8X2” Panel, Fender Assembly, QG Washer, Flat, 5/8” X 1 3/4"

003400 608236 003300

Nose, L, Wide, W/Logo Nose, R, Wide, W/Logo Bracket, Cart Support, Nose

611672 611683 605430

* Parts in red are included in assemblies.

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Nose, L, Narrow, W/Logo Nose, R, Narrow, W/Logo Bracket, Cart, Nose

611669 611680 605420

Bolt, Hex, 5/8” X 2 1/2", G5 Bolt, Hex, 1/4" X 3/4", G5 Bracket, Cartridge Support

118232 113518 605446

Bolt, Bt, 5/8” X 1 1/4", Hex

Bolt, Hex, 5/8” X 2”, G5 Nut, Hex, 1/4"

Socket

113404 118570 115946

Nut, Hex, Coupling, 5/8” 11” X

Washer, Lock, 1/4" Washer, Lock, 5/8”

2 1/8”

115986 118085 118100

* Parts in red are included in assemblies.

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Bracket, Angle, 2” X 1”, W/Holes

Washer, Flat 3/8” X 1” Nut, Hex, 3/8”

617387 118036 115960

Bolt, Hex, 3/8” X 1”,G5 Washer, Fender, 3/8” X 2” Bolt, Hex, 5/8” X 1 1/2", G5

113596 118038 113654

Bracket, Pull-Out Shim Kit, 1/8” X 3 5/8” X 8”(2) Washer, Lock, 3/4"

605535 614050 118089

Bolt, Hex, 3/4" X 2”, G8 Monorail Guide Nut, Heavy Hex, 3/4”

113555 611368 003704

* Parts in red are included in assemblies.

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Nut, Heavy Hex, 5/8” Hinge Plate, Fender Panel Bolt, Hex, 5/8” X 4”, G5

003354 610172 113666

Panel, Side, QG Bracket, Cartridge Support

TS B/U

Locking Bar, Cartridge Support

611898 605447 611266

Anchor Kit, Hilti, 3/4” X 7” (4) * Stud, 3/4” X 7”, G5 Washer, Flat, 3/4” X 2”

619316 117542 118027

*See Trinity Highway Approved Adhesive Anchoring System section on page 16.

Cartridge Assy, Type I Cartridge Assy, Type II

606027 606029

* Parts in red are included in assemblies.

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Foundation/Anchoring

Important: It is the responsibility of the local DOT or appropriate authority to

ensure this assembly conforms to the AASHTO Roadside Design Guide.

Warning: It is the responsibility of the installer to ensure that your assembly

procedure meets all appropriate Occupational Safety and Health Administration (OSHA) and local standards.

Asphalt Installations

QuadGuard construction zones on asphalt. Assemblies on Asphalt Concrete (“A.C.”) must provide a minimum of 3” [76 mm] layer of asphalt over a minimum of 3” [76 mm] layer of Portland Cement Concrete (“P.C.C.”), 6” [152 mm] layer of asphalt over 6” [152 mm] layer of subbase, or 8” [203 mm] layer of asphalt with no subbase.

Concrete Installations

For concrete installations, the QuadGuard placed and cured concrete base (4000 psi [28 MPa] minimum). Orientation of the concrete base and the attenuator must comply with the project plans or as otherwise determined by the project engineer or appropriate highway authority.

The QuadGuard anchorage:

II Narrow systems with a Tension-Strut Backup may be temporarily installed in

Important: Only 18” [460 mm] threaded rods, utilizing Trinity Highway approved

adhesive, can be used with asphalt foundations. Contact Customer Service for a complete list of approved adhesives (p. 3).

II should be installed only on an existing or freshly

II may be installed on any of the following foundations using the specified

Foundation A: Concrete Pad or Roadway

Foundation: 6” [150 mm] minimum depth P.C.C. Anchorage: Approved adhesive

with 7” [180 mm] studs 5 1/2” [140 mm] embedment

Foundation B: Asphalt over P.C.C.

Foundation: 3” [76 mm] minimum A.C. over 3” [76 mm] minimum P.C.C. Anchorage: Length of anchor required is 18” [460 mm] 16 1/2” [420 mm] embedment Foundation C: Asphalt over Compacted Subbase (“C.S.”) Foundation: 6” [150 mm] minimum A.C. over 6” [150 mm] minimum C.S. Anchorage: Approved adhesive with 18” [460 mm] studs 16 1/2” [420 mm] embedment

Foundation D: Asphalt Only

Foundation: 8” [200 mm] minimum A.C. Anchorage: Approved adhesive with 18” [460 mm] studs - 16 1/2” [420 mm] embedment

Important: Systems mounted on asphalt must be replaced and mounted on

fresh, undisturbed asphalt if more than 10% of anchors are found to be loose, broken, or show signs of pull out. If 10% or fewer anchors are damaged, replace the damaged anchors in the existing asphalt. Anchor bolts used on systems mounted on asphalt must be inspected every six months. See Post Impact Instructions and Maintenance and Repair instructions on page 58.

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Recommended Tools

Documentation

 Manufacturer’s Assembly Manual  Manufacturer’s Drawing Package

Personal Protective Equipment

 Eye Protection  Gloves  Safety Toe Shoes

Cutting Equipment

 Rotary Hammer Drill  Rebar Cutting Bit  Concrete Drill Bits – 7/8” [22 mm] (Double-Fluted)  Grinder, Hacksaw or Torch (optional)  Drill Bits 1/16” through 7/8”

Important: Trinity Highway recommends using double-fluted drill bits to achieve

optimum tensile strength when applying an approved adhesive to the anchoring system (p. 16).

Hammers

 Sledgehammer  Standard hammer

Wrenches

 Heavy Duty 1/2” drive impact wrench  1/2" drive Sockets: 9/16", 11/16", 3/4", 15/16", 1 1/8", 1 1/4"  1/2" drive Deep Well Sockets: 15/16", 1 1/4”  1/2" drive Ratchet and Attachments  1/2" drive Breaker Bar – 24” long  1/2" drive Torque Wrench: 200 ft-lb  Crescent Wrench: 12” [300 mm]  Allen Wrench: 3/8”

Important: Trinity Highway makes no recommendation whether use or

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Miscellaneous

 Traffic Control Equipment  Lifting and moving equipment (A lifting device is preferred although a forklift can be used.)

Minimum 5,000 lb. capacity required.

 Air Compressor (100 psi minimum) and Generator (5 kW)  Long Pry Bar  Drift Pin 12” [300 mm]  Center Punch  Tape Measure 25’ [7.5 m]  Chalk Line  Concrete Marking Pencil  7/8” Diameter steel tube brush for cleaning drilled boreholes  Rags, water, and solvent for clean up

Note: The above list of tools is a general recommendation and should not be considered

an exhaustive list. Depending on specific site conditions and the complexity of the assembly specified by the appropriate highway authority the required tools may vary. Decisions as to what tools are needed to perform the assembly properly are entirely the responsibility of the specifying highway authority and the authority’s selected contractor performing the assembly of the system at the authority’s specified assembly site.

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Site Preparation/Foundation

A QuadGuard® II system should be assembled only on an existing or freshly placed and cured concrete base (28 MPa [4000 psi] minimum). Location and orientation of the concrete base and attenuator must comply with project plans or as otherwise determined by the local highway authority.

Recommended dimension and reinforcement specifications for new concrete foundations are provided in Trinity Highway concrete foundation drawings, supplied with the system. The system may be assembled on a non-reinforced concrete roadway (minimum 8” [200 mm] thick). Deployment cross-slope shall not exceed 8% and should not twist more than 2% over the length of the system; the foundation surface shall have a light broom finish.

Warning:

location for the QuadGuard Guide. Trinity Highway is not responsible for choosing the location for system placement.

Warning:

by the state or specifying agency pursuant to the AASHTO Roadside Design Guide.

Caution:

the concrete anchor bolts.

It is the responsibility of the appropriate highway authority to select the

Ensure proper site grading for QuadGuard® II placement as directed

Accurate placement of all steel rebar is critical to avoid interference with

II in accordance with the AASHTO Roadside Design

Figure 1

Cross-Slope

Warning:

operation of the attenuator. Upon impact, the Fender Panels are designed to telescope rearward and extend beyond the rigid Backup as much as 30” [760 mm] from their pre-impact location. Position the Backup so that the rear ends of the last Fender Panels are a minimum of 30” [760 mm] forward of objects that would otherwise interfere with movement of the rearmost Fender Panels. Failure to comply with this requirement is likely to result in system performance that has not been crash tested pursuant to NCHRP Report 350 criteria and may also cause component damage which will necessitate maintenance or replacement of the system.

Important:

to ensure the instructions provided in this manual have been strictly followed.

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Location of the Backup in relation to nearby objects will affect the

It is critical that you inspect this product after assembly is complete

Page 17

Trinity Highway Approved Adhesive Anchoring System

A Trinity Highway approved adhesive anchoring system is required to securely anchor crash cushions. Each approved adhesive kit contains adhesive, studs, nuts and washers. Both vertical and horizontal assemblies are possible using an approved adhesive anchoring system.

Vertical Assemblies

Note: Read all Trinity Highway approved adhesive instructions before starting.

1) Prepare the Concrete Foundation

Warning: Do not allow anchoring adhesive to contact skin or eyes. See safety

data sheet supplied with adhesive kit for first-aid procedures. Use only in wellventilated area. Do not use near open flame.

Warning: Wear gloves and eye protection during application.

The studs that anchor the QuadGuard foundation must be those shipped in the kit or of high strength steel (120,000 psi [830 MPa] minimum tensile strength or equal). These studs must be set in minimum 4000 psi [28 MPa] concrete. Allow the concrete to cure a minimum of seven days before applying anchoring adhesive.

II Backup and/or Monorail sections to the concrete

2) Drill Boreholes

Caution: It is the responsibility of the installer to consult OSHA silica

respiratory standard 29 CFR 1910.134 for debris removal from borehole(s) and use Trinity Highway approved adhesive to achieve optimum tensile strength. Do not use diamond drill bits for drilling boreholes.

Use the Monorail(s) and Tension Strut Backup as drilling templates. Use a rotary hammer drill to drill the boreholes 7/8” [22 mm] diameter to the recommended depth. See the approved adhesive instructions provided with your kit. Check to ensure each borehole is drilled to the proper depth and aligned with the part to be anchored per chart below.

Anchoring Information

Stud Size: Orientation Bit Size Minimum Depth Torque Medium

3/4”x 6 1/2" Horizontal 7/8” [22 mm] 5 1/4” [133 mm] Manufacturer Spec Concrete

3/4”x 7" Vertical 7/8” [22 mm] 5 3/4” [145 mm] Manufacturer Spec Concrete

3/4”x 18" Vertical 7/8” [22 mm] 16 3/4” [425 mm] 10 ft-lb [15 N-m] Asphalt

Important: When mounting on asphalt, initial torque shall be as shown

above. Due to the properties of asphalt, anchors may loosen over time. For this reason Trinity Highway recommends anchoring to asphalt only at temporary locations. It is recommended to re-torque anchors in asphalt every six (6) months to the proper initial torque specified.

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Page 18

3) Clean the Boreholes

Blow the concrete dust from the borehole using oil-free compressed air. Thoroughly brush it with a 7/8” diameter steel bristle tube brush and then blow it out again. If the borehole is wet, completely flush it with water while brushing and then blow it clean to remove all water using oil-free compressed air.

Note: Use of the Trinity Highway approved vacuum drilling equipment is authorized to replace

the blowing and brushing requirement of Step 3.

4) Apply Approved Adhesive

Fill the borehole 100% full.

Caution: Fill borehole 100% full so it is even with the pavement surface per

manufacturer’s instructions.

5) Add Nuts to Anchor Studs

Place a flat washer onto the stud then thread a nut on until the end of the stud is flush with the nut (Figure 2).

6) Insert Studs in Boreholes and Wait for Adhesive to Cure

Push the stud down through the part to be anchored and into the borehole.

Caution: Do not disturb or load the stud until the approved

adhesive material has hardened (see instructions supplied with the approved adhesive kit).

7) Torque the Nuts

Once the adhesive has fully cured, torque the nut to the adhesive manufacturer’s recommended values.

Figure 2

Vertical Application

(Before Applied Torque)

Anchor Assembly Cautions

1) Steel rebar

If steel rebar is encountered while drilling an anchor bolt borehole, apply one of the following solutions:

A) Use a rebar drill bit for the rebar only and then switch back to the concrete bit to finish

drilling into the underlying concrete until the proper borehole depth is reached.

Caution: Do not drill through rebar without first obtaining permission to do so

from the project engineer.

B) Drill a new borehole down at an angle past the rebar to the proper depth. Anchor the

stud by completely filling both boreholes with an approved adhesive.

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Page 19

Horizontal Assemblies

The horizontal approved adhesive kit is the same as the vertical kit.

Caution:

manufacturer’s instructions.

1) Follow the instructions supplied with your approved adhesive kit

Apply approved adhesive to each anchor per instructions.

2) Add the Washers and Nuts

Put washer and nut on stud so the nut is flush with end of stud.

3) Insert each Stud with Washer and Nut into Borehole

Push stud with washer and nut into borehole.

Important:

horizontal applications prior to tightening (Figure 3).

Fill borehole 100% full so it is even with the surface of the hole per

The stud should be flush with the top of the nut in both vertical and

Horizontal Application

(Before Applied Torque)

Warning:

has hardened (see approved adhesive kit instructions for cure times and torque values).

4) Torque the nuts

Once the adhesive has fully cured, torque nut(s) to the approved adhesive manufacturing specification.

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Do not disturb or load the stud until the approved adhesive material

Figure 3

Page 20

QG2100126

Figure 4 Plans & Elevation

(Five Bay systems with Tension Strut Backups shown, except as noted)

Key

1) Cartridge

2) Diaphragm

3) Quad-Beam Fender Panel

4) Nose

5) Monorail

6) Backup

7) Side Panel

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How to Determine Left/Right

To determine left from right when ordering parts, stand in front of the system facing the roadside feature. Your left is the system’s left and your right is the system’s right.

Counting the Number of Bays

One Bay consists of one Cartridge, one Diaphragm, two Fender Panels, etc. The Nose section is not considered a Bay, though there is a Cartridge in the Nose of each system (pp. 63 & 64).

Note:

the system. To determine number of Bays, count Fender Panels on one side (Figure 5). The

Three Bay system is shown below.

There will always be one more Cartridge in the system than the number of Bays in

REAR

BAY

FENDER PANELS

DIAPHRAGM

BAY

CARTRIDGE

RIGHT

NOSE

FRONT

LEFT

Figure 5

System Orientation

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Measuring the Width

The QuadGuard® II system is available in seven (7) nominal widths:

 24” [610 mm]  30” [760 mm]  36” [915 mm]  48” [1219 mm]  69” [1755 mm] – (Minimum 3 Bays Required)  90” [2285 mm] – (Minimum 3 Bays Required)  126” [3200 mm] – (Minimum 6 Bays Required)

The nominal width of a Narrow (parallel) system is the width of the Backup diaphragm (Figure

6). The nominal width of a Wide (flared) system is the width at the location shown in Figure 7. The outside or overall width of the system is approximately 6” [150 mm] to 9” [230 mm] wider than

the nominal width.

Figure 6

Narrow (Parallel) System

Figure 7

Wide (Flared) System

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Narrow (Parallel) Systems

610 mm [24”] Model No. QG2 _ _24

760 mm [30”] Model No. QG2 _ _30

915 mm [36”] Model No. QG2 _ _36

1219 mm [48”] Model No. QG2 _ _48

Narrow System(s) and Model Numbers

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Figure 8

Page 24

Assemble Narrow (Parallel)

Determine Backup and Transition Type

The QuadGuard® II is available with a Tension Strut Backup or a Concrete Backup. Refer to Figures 9 and 10, along with the Backup Assembly drawing, to determine which type of Backup is being deployed.

A Transition Panel or Side Panel must be used on each side of the Backup. A Side Panel is not needed when a Transition Panel is used. Several types of Transitions are available for use with the QuadGuard Package to determine which type of Panels to attach.

II. Refer to Figures 11 - 16 and the Manufacturer’s Drawing

610 mm [24”] 760 mm [30”] 915 mm [36”] 1219 mm [48”]

WIDTH VARIES*

Figure 9

Tension Strut Backup

*610 mm [24”] *760 mm [30”] *915 mm [36”] *1219 mm [48”]

Figure 10

Concrete Backup

QUAD-BEAM TO W-BEAM

TRANSITION PANEL

Figure 11

Transitioning the QuadGuard

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Note:

The proper Transition Panel or Side Panel must be used for impact performance of the system. The correct Panel(s) to use will depend on the direction of traffic and what type of barrier or roadside obstacle the QuadGuard

II is shielding. Contact Customer Service prior to

deployment if you have any questions (p. 3).

Figure 12

No Transition

Quad-Beam to Safety Shape Barrier

Figure 13

Quad-Beam to Thrie-Beam

Figure 14

Quad-Beam to W-Beam

Figure 15

Quad-Beam End Shoe

Figure 16

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1) Mark System Location

Locate the centerline of the system by measuring the proper offset from the roadside feature. See the Manufacturer’s Drawing Package supplied with the system. Place chalk line to mark the centerline of the system. Mark a construction line parallel to the center line and offset 6.5” [165 mm] to one side as shown in Figure 17. The edge of the Monorail will

be positioned on this line.

Note:

The concrete foundation shall comply with the Manufacturer’s Drawing Package supplied with the system.

Warning:

Location of system with respect to the roadside obstacle is critical and dependent on the type of Transition Panel used. See the Manufacturer’s Drawing Package supplied with the system for details.

(Top view of concrete foundation)

Figure 17

2) Anchor the Backup A) Concrete Backup Construction (Figure 18) Locate Backup Face Plate using the Backup Assembly drawing. Verify that any applicable

Transition Panels fit properly before anchoring the Face Plate. Drill anchor boreholes

in the Concrete Backup using the Face Plate as a template. Anchor the Face Plate to the Concrete Backup using an approved adhesive supplied with the QuadGuard

II (p. 16).

A Trinity Highway approved adhesive anchoring system is required to securely anchor crash cushions and other common highway devices. Each approved adhesive kit contains adhesive, studs, nuts and washers. Both vertical and horizontal assemblies are possible using an approved adhesive anchoring system.

Warning:

Every hole in the Backup and Monorail must be anchored using an

approved adhesive (p. 16).

B) Tension Strut Backup Assembly (Figure 19)

Locate Tension Strut Backup and Monorail on foundation with side of Monorail on the construction line (Figure 20 on p. 27). Verify that any applicable Transition Panels fit properly before anchoring Backup. Drill 7/8” [22 mm] diameter by 5 3/4” [145 mm] deep

anchor boreholes in foundation using the Backup as template. Anchor the Backup to the concrete foundation using an approved adhesive supplied with the QuadGuard II (p. 16).

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FULLY CURED CONCRETE BACKUP

SEE MANUFACTURER’S DRAWING PACKAGE

BACKUP FACE PLATE

PPROVED ADHESIVE WITH

3/4” X 6 1/2” STUD

Figure 18

Anchoring Backup Face Plate to

Concrete Backup

TENSION STRUT

Anchoring Tension Strut Backup

Figure 19

to Foundation

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Anchor the Monorail A) Monorail Placement for Concrete Backup (Figure 20)

Locate Monorail on foundation with side of Monorail on the construction line and rear edge of Monorail foot 10” forward of front face of Concrete Backup (Figure 20).

Orient the Monorail so that the Monorail tongues face Backup (Figure 20). Drill 7/8” [22 mm] diameter by 5 3/4” [145 mm] deep boreholes using the Monorail as a

template. Do not drill through foundation.

Warning:

Improper alignment at the Monorail Sections will prevent proper

system collapse during impact (Figure 23).

Anchor each Monorail section using an approved Trinity Highway adhesive kit. See Figure 20 and the approved adhesive instructions included with the adhesive kit. It is important to attach each segment of Monorail in alignment from the back to the front of the system (±1/4” [6 mm]).

Warning:

Every borehole and slot in Backup and Monorail must be anchored by

a stud using an approved adhesive.

Figure 20

Monorail Placement for Concrete Backu

ANCHOR

NUT

WASHER

ROADWAY

CAUTION: 40 MM [1.5”] MAXIMUM STUD HEIGHT (TORQUE APPLIED)

BACKUP OR MONORAIL

Figure 21

Proper Stud Height

(Torque Applied)

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B) Monorail Placement for Tension Strut Backup (Figure 22)

Locate Monorail on foundation with side of Monorail on the construction line and rear edge of Backup foot 4” forward of edge of foundation (Figure 22).

Orient the Monorail so that the Monorail tongues face the Backup (Figure 23).

Drill 7/8” [22 mm] diameter by 5 3/4” [145 mm] deep boreholes using the Monorail as a template. Do not drill through foundation.

Warning:

Every borehole and slot in Backup and Monorail must be anchored by

a stud using a Trinity Highway approved adhesive.

Anchor each Monorail section using the Trinity Highway approved adhesive kits provided. See Figure 21 and the approved adhesive instructions included with each kit. It is important to attach each segment of Monorail in alignment from the back to the front of the system

(±1/4” [6 mm]).

Warning:

Improper alignment at the Monorail splice joints will prevent proper

system collapse during an impact (Figure 23).

Figure 22

Backup and Monorail Placement for Tension Strut Backup

It is important to align each segment of Monorail from the back to the front of the system (±1/4” [6 mm]). Anchor each Monorail section using the provided Trinity Highway approved adhesive kit.

Drill 7/8” [22 mm] diameter by 5 3/4” [145 mm] deep boreholes using the Monorail as a template. Do not drill through foundation.

Top surfaces

must be flush

Tongues must be

Detail 23a

Fully Inserted and Flush

Figure 23

Rail Height and Alignment

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4) Attach Side Panels and/or Transition Panels to Backup Assembly

Attach Transition Panel or Side Panel to side of Backup using 5/8” X 2” rail bolt and 5/8” rail nut (two places - top and bottom holes only). See Backup Assembly drawing(s) below.

Note: A Side Panel is not needed when a Transition Panel is used.

Assembly tip:

Use drift pin to align the center hole of the Panel with the center hole of the Backup before inserting the rail bolts.

TENSION STRUT BACKUP

NARROW SIDE PANEL

5/8” RAIL NUT (2) (FIGURE 28)

CONCRETE BACKUP

5/8” X 2 RAIL BOLT (2)

SIDE PANEL SHOWN HERE

IN SOME CASES, THIS WILL BE

A TRANSITION PANEL

(p. 24)

Side Panel/Transition Panel Attachment

Figure 24

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5) Attach Monorail Guides

Attach Monorail guides to Diaphragm as follows: Insert 3/4" x 2” G8 hex bolt through Monorail guide and Diaphragm, oriented as shown in

Figure 25. Secure with 3/4" lock washer and 3/4" hex nut (typical 4 places). See also Diaphragm Assembly drawing. Shims are sandwiched between the Rail Guide and Diaphragm.

Repeat process for each Diaphragm.

6) Attach Diaphragms

Orient a Diaphragm so that the front face of the Diaphragm shape faces toward the Nose of the system as shown in Figure 26.

Important:

Slide one Diaphragm all the way to the Backup to ensure the system

is able to collapse properly during impact. Once this has been verified, slide the Diaphragm to approximately 36” [915 mm] in front of the Backup

Orient and slide all other Diaphragms onto Monorail and position each approximately as shown in Figure 27.

DIAPHRAGM

MONORAIL GUIDE

Monorail Guide Attachment

SHIM

Figure 25

3/4” LOCK WASHER

3/4” HEX NUT

3/4” X 2 G8 HEX BOLT

Figure 26

Diaphragm Orientation

Bay 3

Figure 27

Bay 2

Bay 1

Nose

Diaphragm Spacing

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7) Attach Fender Panels

Important:

(Figure 28).

Starting at the Backup, attach left and right Fender Panels shown on page 32 and Fender Panel Assembly drawing.

Step 1

Do not mix the 5/8” rail nuts (large) with the 5/8” hex nuts (small)

Figure 28

Rail Nuts are Oversize

Place the Fender Panel so that the center of the slot of the rearward Diaphragm is lined up with the approximate center of the slot in the Fender Panel.

Install the Mushroom Washer Assembly as shown in Figure 29 and Detail 29a and Detail 29b, but do not torque at this time. This (Step 1) helps to balance the Fender Panel.

Step 2

Slide the Fender Panel forward until the holes in the Fender Panel line up with the holes in the forward Diaphragm.

Step 3

Use a drift pin to align the center hole of the Fender Panel with the center hole of the Diaphragm.

Step 4

Attach the front of the Fender Panels to the next Diaphragm using two (2) rail bolts and large rail nuts per side. Use only the top and bottom holes; leave the center hole open until the next Fender Panel is attached.

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BACKUP OR DIAPHRAGM

1 1/2” SPRING

SIDE PANEL,

FENDER PANEL, OR

TRANSITION PANEL

MUSHROOM WASHER

5/8” X 5” FLATHEAD

SOCKET SCREW

Step 5

FENDER PANEL

5/8” RAIL BOLT

5/8” HEX NUT (SMALL)

5/8”X 1 3/4” FLAT WASHER

5/8” RAIL NUT (LARGE)

5/8” RAIL BOLT

KEEP CENTER HOLE EMPTY FOR NEXT PANEL

Figure 29

Fender Panel Assembly

DIAPHRAGM

5/8” RAIL NUT (LARGE)

Ensure Mushroom Washer lays flat against the Fender Panel as shown in Figure 29b. Standoff on Mushroom Washer must be seated completely through slot.

FENDER PANEL

MUSHROOM WASHER

5/8” X 5” FLATHEAD

SOCKET SCREW

FENDER PANEL (ATTACHED)

BACKUP OR DIAPHRAGM

SLOT

Detail 29a

Mushroom Washer Attachment

1 1/2” SPRING

SLOT

5/8” HEX NUT (SMALL)

5/8” FLAT WASHER

Detail 29b

Mushroom Washer Orientation

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Step 6

Check Diaphragm spacing to ensure 36” [915 mm] between rear faces of consecutive Diaphragms, as shown in Figure 30 and Fender Panel Assembly drawing.

Step 7

Once proper spacing has been achieved, tighten the Mushroom Washer Assembly (small hex) nut until it reaches the end of the threads. Tighten rail nut (large hex) at the front of the Fender Panels. Ensure rail bolt shoulder is seated within the Fender Panel slot.

Assemble the remaining Diaphragms and Fender Panels following the same procedures.

Proper Diaphragm Spacing

Figure 30

8) Attach End Cap (Figure 31)

Using a 5/8” x 3 1/2" G5 hex bolt, 5/8” hex nut, and 5/8” lock washer, attach the End Cap to the front of the first Monorail segment.

Figure 31

Monorail End Cap Assembly

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9) Attach Cartridge Support Brackets (Figure 32)

Attach lower Cartridge Support Bracket to front and back of all Diaphragms and front of Backup, as shown in Figures 32 to 35 and Backup Assembly drawings.

Note: 24” [610 mm] wide systems do not have Side Cartridge Support Brackets: 30” [760 mm],

36” [915 mm] and 48” [1219 mm] wide systems have Side Cartridge Support Brackets welded to the Backup and Diaphragms.

24” [610 mm] WIDE

30” DIAPHRAGM

30” [762 mm] WIDE

36” [915 mm] WIDE

SIDE CARTRIDGE SUPPORT BRACKETS

Figure 32

Side Cartridge Support Brackets

DIAPHRAGM

CARTRIDGE SUPPORT BRACKET

Figure 33

Lower Cartrid

e Support Bracket Assembl

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Page 36

TENSION STRUT BACKUP [30” shown]

STEP II MOUNT LOCKING BAR

STEP I MOUNT CARTRIDGE SUPPORT BRACKET

CONCRETE BACKUP

FACE PLATE

CARTRIDGE SUPPORT BRACKET

TENSION STRUT BACKUP

Lower Cartridge Support Bracket Assembly

(Tension Strut Backup)

Figure 34

Lower Cartridge Support Bracket

CARTRIDGE SUPPORT BRACKET

CARTRIDGE SUPPORT BRACKET IS WELDED TO FACE PLATE OF CONCRETE BACKUP

Figure 35

(Concrete Backup)

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10) Attach Steel Nose Assembly

A) Install two (2) 5/8” X 2” hex bolts and one (1) 5/8 X 2 1/2” hex bolt with Pullout Bracket

through Diaphragm side plate. Fasten all three (6 total) bolts with 5/8” rail nuts on each side and tighten (Detail 36A).

B) Thread 5/8” coupling nuts on 5/8” hex bolts to align with outside of Fender Panel (Detail

36B).

C) Join Steel Nose halves using 1/4” X 3/4” hex bolts, lock washers and nuts. Include

Cartridge Support Nose Bracket in lower two fastener sets (Detail C & D).

D) Attach Steel Nose to Diaphragm using 5/8” X 1 1/4” hex socket bolt and 5/8” x 1 1/4” flat

washer (Detail 69E). Steel Nose top edge should be 32 1/8” above concrete surface.

E) Place the Cartridge Support Bracket on the front of the first Diaphragm (Detail 36F).

Place a Type I Cartridge in the Nose Bay.

STEEL NOSE ASSEMBLY

IEWS 36A - F

FENDER PANEL

RAIL N

Figure 36

5/8” X 2” HEX BOLT

5/8” X 2 1/2” HEX BOLT

5/8” RAIL NUT

PULLOUT BRACKET

DIAPHRAGM

5/8” COUPLING NUT

LIGN END OF

COUPLING NUT WITH

OUTSIDE HUMPS OF

FENDER PANEL

5/8” X 2” HEX BOLT

Detail 36A

Fastener Assembly

End View: Nose Cover Cut Away

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Detail 36B

Page 38

HEX BOLT 1/4 X 3/4

Detail 36C

LOCK WASHER 1/4” HEX NUT 1/4”

Detail 36C

Total Six 1/4-20 Fasteners

Nose Cartridge

Support Bracket

Detail 36D

5/8” X 1 1/4" HEX SOCKET BUTTON BOLT

5/8” FLAT WASHER

Note height of Nose Cartridge Support Bracket. The Cartridge sits 2” lower on this Bracket than other Bays toward the rear.

Detail 36E

Detail 36F

Detail 36D shows proper placement of front Cartridge Support Bracket.

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11) Checking the System Assembly

Recheck to ensure that all fasteners are properly tightened throughout the system (anchor

bolts, etc.). See torque requirements below. Check all Fender Panels. If they do not fit tightly

against the underlying Fender Panel, system realignment may be necessary (Figure 37). Verify the top of the Steel Nose is 32 1/8” above the roadway (p. 36).

Warning:

Ensure that the QuadGuard® II and delineation used meet all federal,

state, specifying agency, and local specifications.

Warning:

Ensure delineation on the assembly meets all ap propriate MUTCD and

local standards.

Warning:

Anchor Requirements Anchor Studs – Anchoring Information Table, p. 16 May slightly protrude above nuts

Critical Clearances Anchor Studs above nuts – Figure 21, p. 27 Fender Panel Gap Narrow – 7/8” [22 mm] see below

MAXIMIM GAP = 7/8” [22 mm]

UNDERLYING FENDER, TRANSITION,

EXTENTION OR SIDE PANEL

FENDER PANEL

Figure 37

Fender Panel Gap for Narrow Systems

13) Cartridge Placement

Be sure the Adjustable Cartridge Support in the Nose is attached correctly (p. 37). The top

surface of the Nose Cartridge should be horizontal.

To complete the assembly of a QuadGuard

II, place the appropriate Cartridge in each Bay and Nose section of the system. Type 1 Cartridges are placed toward the front (Nose) of the system; Type 2 Cartridges are placed toward the rear (Backup) of the system (Figures 38 and 39). Ensure all Cartridges are pointed toward the front of the system per Cartridge direction arrow(s).

Warning:

Placing the wrong Cartridge in the Nose or any Bay will result in system performance that has not been crash tested pursuant to the NCHRP Report 350 criteria.

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Page 40

Figure 38

Cartridge Placement

Type 2

Figure 39

Five Bay System

Type 1

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Page 41

Wide (Flared) Systems

[

(Min. 3 Bays) 1755 mm [69”] Model No. QG2 _ _ 69

(Min. 3 Bays) 2285 mm [90”] Model No. QG2 _ _ 90

Varies - (Min. 6 Bays) 3200 mm

126”] Model No. QG2 _ _ 126

Figure 40

Wide System(s) and Model Numbers

10 Deg.

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Page 42

Assemble Wide (Flared)

Important:

The Manufacturer’s Drawing Package supplied with the QuadGuard® II must be used with these instructions for proper assembly and should take precedence over these general instructions.

Determine Backup and Transition Type

The QuadGuard® II is available with a Tension Strut Backup or a Concrete Backup. See

Figures 41 and 42, along with the Backup assembly drawing, to determine which type of Backup is being deployed.

A Transition Panel or Side Panel must be used on each side of the Backup. A Side Panel is not needed when a Transition Panel is used. Several types of transitions are available for use with the QuadGuard Package to determine which types of Fender Panels to attach.

II. See Figures 44 through 48 and the Manufacturer’s Drawing

Tension Strut Backup

Figure 41

QUAD-BEAM TO W-BEAM

TRANSITION PANEL

Figure 42

Concrete Backup

Figure 43

QuadGuard

II Transitioning

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Page 43

Important:

The proper Transition Panel or Side Panel must be used to perform

as crash tested. The correct Panel(s) to use will depend on the direction of

traffic and what type of barrier or roadside obstacle the QuadGuard

II is

shielding. Contact Customer Service prior to deployment if you have any

questions (p. 3).

Figure 44

No Transition

Note: Arrows indicate traffic direction.

Figure 46

Quad-Beam to Thrie-Beam

Figure 45

Quad-Beam to Safety Shape Barrier

Figure 47

Quad-Beam to W-Beam

Note: Arrows indicate traffic direction.

Figure 48

Quad-Beam End Shoe

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Page 44

1) Mark System Location

Locate the centerline of the system by measuring the proper offset from the roadside obstacle. See the Manufacturer’s Drawing Package supplied with the system. Place chalk line to mark the centerline of the system. Mark a construction line parallel to the center line and offset

6.5” [165 mm] to one side as shown in Figure 49. The edge of the Monorail will be placed on this line.

Note:

The concrete foundation shall comply with the Manufacturer’s Drawing Package supplied

with the system.

Warning:

Location of system with respect to the roadside object is critical and dependent on the type of Transition Panel used. See the Manufacturer’s Drawing Package supplied with the system for details.

(Top view of concrete foundation)

Figure 49

2) Anchor the Backup A) Concrete Backup Construction (Figure 50)

Locate Backup Face Plate using the Backup assembly drawing. Verify that any applicable Transition Panels fit properly before anchoring the Face Plate. Drill anchor boreholes

in the Concrete Backup using the Face Plate as a template. Anchor the Face Plate to the

Concrete Backup using an approved adhesive supplied with the QuadGuard

II (p. 16).

A Trinity Highway approved adhesive anchoring system is required to securely anchor crash cushions and other common highway devices. Trinity Highway approved adhesive features high pullout strength, vibration resistance, and durability. Each approved adhesive kit contains adhesive, studs, nuts and washers. Both vertical and horizontal assemblies require an approved adhesive anchoring system.

Warning:

Every borehole and slot in Backup and Monorail must be anchored by

a stud using an approved adhesive.

B) Tension Strut Backup Assembly (Figure 51)

Locate the Tension Strut Backup and Monorail on foundation with side of Monorail on the construction line (p. 47). Verify that any applicable Transition Panels fit properly before anchoring Backup. Drill 7/8” [22 mm] diameter by 5 3/4” [145 mm] deep anchor boreholes in foundation using the Backup as template. Anchor the Backup to the concrete

foundation using the Trinity Highway approved adhesive supplied with the QuadGuard

(p. 16).

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Page 45

FULLY CURED CONCRETE BACKUP (SEE MANUFACTURER’S DRAWING PACKAGE)

APPROVED ADHESIVE

WITH 3/4" X 6 1/2” STUD

BACKUP FACE PLATE

Figure 50

Anchoring Backup Face Plate to Concrete Backup

TENSION STRUT BACKUP

Anchoring Tension Strut Backup to Foundation

Figure 51

PPROVED ADHESIVE

WITH 3/4" X 7” STUD

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C) Extra-Wide Tension Strut Backup Assembly (Figure 52)

Locate the Extra-Wide Tension Strut Backup center section and Monorail on foundation with side of Monorail on the construction line.

Locate the Extra-Wide Tension Strut Backup left section on the left side of the center section, aligning the three holes in the side plates.

Locate the Extra-Wide Tension Strut Backup right section on the right side of the center section, aligning the three holes in the side plates.

Secure the Backup sections to each other using 5/8” x 2” hex bolt, 5/8” x 1 3/4" flat washer (2), 5/8” lock washer and 5/8” hex nut (6 places) as shown in Figure 52 and Detail 52a.

Verify that any applicable Transition Panels fit properly before anchoring Backup. Drill anchor boreholes in foundation using the Backup as template. Anchor the Backup to the foundation using Trinity Highway approved adhesive kits supplied with the

QuadGuard

II (p. 16).

Warning: Every borehole and slot in Backup and Monorail must be anchored by

a stud using a Trinity Highway approved adhesive.

-WIDE

EXTR TENSION STRUT BACKUP RIGHT SECTION

EXTR

-WIDE TENSION STRUT BACKUP CENTER SECTION

DETAIL 52a

-WIDE

EXTR TENSION STRUT BACKUP LEFT SECTION

Figure 52

Anchoring Extra-Wide Tension Strut Backup to Foundation

PPROVED ADHESIVE

WITH 3/4" X 7” STUD

5/8” X 2” HEX BOLT

5/8” X 1 3/4” FLAT WASHER

5/8” LOCK WASHER

5/8” HEX NUT

Detail 52a

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Page 47

3) Anchor the Monorail A) Monorail Placement for Concrete Backup (Figure 53)

Locate Monorail on foundation with side of Monorail on the construction line and rear edge of Monorail 10” forward of front face of Concrete Backup. Orient the Monorail so that the Monorail tongues face Backup (Figure 53).

Drill 7/8” [22 mm] diameter by 5 3/4” [145 mm] deep boreholes using the Monorail as a template. Do not drill through foundation.

Warning:

Improper alignment at the Monorail Splice Joints may prevent proper

system collapse during impact (Figure 56).

Anchor each Monorail section using an approved adhesive kit (p. 16). It is important to attach each segment of Monorail in alignment from the back to the front of the system (±1/4” [6 mm]).

Warning:

Every borehole and slot in Backup and Monorail must be anchored by

a stud using an approved adhesive.

Monorail Placement for Concrete Backup

Figure 53

ANCHOR

NUT

WASHER

ROADWAY

CAUTION: 40 mm [1.5”] MAXIMUM STUD HEIGHT

BACKUP OR MONORAIL

Figure 54

Proper Stud Height

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Page 48

Monorail Placement for Tension Strut Backup (Figure 55)

Locate Monorail on foundation with side of Monorail on the construction line and rear edge of Backup 4” forward of edge of foundation. Orient the Monorail so that the Monorail tongues

face the Backup (Figure 56 & Detail 56a). Drill 7/8” [22 mm] diameter by 5 3/4” [145 mm] deep boreholes using the Monorail as a

template. Do not drill through foundation.

Warning:

Every borehole and slot in Backup and Monorail must be anchored by

a stud using an approved adhesive.

Anchor each Monorail section using the Trinity Highway approved adhesive kits provided. See Figure 54 and the approved adhesive instructions included with each kit. It is important to attach each segment of Monorail in alignment from the back to the front of the system (±1/4” [6 mm]).

Warning:

Improper alignment at the Monorail splice joints will prevent proper

system collapse during an impact (Figure 56).

Figure 55

Backup and Monorail Placement for Tension Strut Backup

It is important to align each segment of Monorail from the back to the front of the system (±1/4” [6 mm]). Anchor each Monorail section using the provided Trinity Highway approved adhesive kit.

Drill 7/8” [22 mm] diameter by 5 3/4” [145 mm] deep boreholes using the Monorail as a template. Do not drill through foundation.

Top surfaces

must be flush

Tongues must be

Detail 56a

Fully Inserted and Flush

Figure 56

Rail Height and Alignment

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Page 49

4) Attach Side Panels and/or Transition Panels to Backup Assembly (Figure 57)

a. Attach Hinge Plate to the Transition Panel or Side Panel using 5/8” rail bolt and 5/8”

rail nut (two places – top and bottom holes only).

b. Attach Transition Panel or Side Panel assembly to Backup using 5/8” hex bolt, 5/8”

lock washer and 5/8” hex nut (three places each side of Backup).

c. Attach diagonal brace to Fender Panel and Backup using 3/8” hex bolt, 3/8” lock

washer and 3/8” hex nut (two (2) places per brace: four (4) places per side).

d. Secure each diagonal brace with a 3/8” hex bolt; 3/8” lock washer, and 3/8” hex nut

(two (2) places per brace) as shown in Figure 57.

Note:

A Side Panel is not needed when a Transition Panel is used. Diagonal braces are not

used with some Transition Panels per the Manufacturer’s Drawing Package.

Assembly tip:

Use drift pin to align the center hole of the Panel with the center hole of the Backup before attaching the rail bolts.

TENSION STRUT BACKUP

DIAGONAL BRACE (INNER)

3/8” X 3 1/2" HEX BOLT

3/8” LOCK WASHER

3/8” HEX NUT

DIAGONAL BRACE (OUTER)

CONCRETE BACKUP

8” X 4" HEX BOLT

3/8” X 3 1/2" HEX BOLT

5/8” LOCK WASHER

8” HEX NUT (SMALL)

HINGE PLATE

WIDE SIDE PANEL

3/8” LOCK WASHER

3/8” HEX NUT

5/8” RAIL BOLT

Figure 57

Side Panel/Transition Panel Attachment

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5/8” RAIL NUT (LARGE)

Page 50

5) Attach Monorail Guides

Attach Monorail guides to Diaphragm as follows: Insert 3/4” x 2” G8 hex bolt through Monorail guide and Diaphragm (Figure 58). Check

orientation and secure hex bolt with 3/4” lock washer and 3/4” hex nut (typical two places per guide). See also Diaphragm assembly drawing. Shims are sandwiched between Monorail guides and Diaphragm.

Repeat process for each Diaphragm.

6) Attach Diaphragms

Orient the widest Diaphragm so that the front face of the Diaphragm shape faces toward the Nose of the system as shown in Figure 59. The widest Diaphragm must be attached

closest to the Backup with each subsequent Diaphragm being progressively narrower.

Important:

Slide the widest Diaphragm onto the Monorail and all the way to the Backup to ensure system is able to collapse properly during impact. Once this has been verified, slide the Diaphragm forward to approximately 36” [915 mm] in front of the Backup.

Orient and slide all other Diaphragms onto Monorail and position each approximately as shown in Figure 60.

DIAPHRAGM

MONORAIL GUIDE

Monorail Guide Attachment

915 mm [36”]

SHIM

Figure 58

915 mm [36”]

3/4” HEX NUT

3/4” LOCK WASHER

3/4” X 2 G8 HEX BOLT

Bay 3 & Higher

Diaphragm

Figure 59

Diaphragm Orientation

Diaphragm

Bay 2Bay 3 Bay 1 Nose

Figure 60

Diaphragm spacing

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7) Attach Hinge Plate onto Fender Panels

Important:

Plates.

Attach Hinge Plate on each Fender Panel using two (2) 5/8” rail bolts and two (2) 5/8” rail nuts, using top and bottom holes only, leaving the center-hole open as shown in Figure 62.

Do not mix the 5/8” rail nuts (large) with the 5/8” hex nuts (small).

Figure 61

Rail Nuts are Oversize

For proper impact performance, wide systems must use Hinge

Figure 62

Hinge Plate Assembly

8) Attach Fender Panels

Starting at the Backup, attach left and right Fender Panels as shown in Figure 63.

Step 1

Place the Fender Panel so that the center of the slot of the rearward Diaphragm is lined up with the approximate center of the slot in the Fender Panel.

Install the Mushroom Washer Assembly as shown in Figure 63 and Detail 63A, but do not torque at this time (this will help to balance the Fender Panel).

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Step 2

Slide the Fender Panel forward until the holes in the Fender Panel line up with the holes in the forward Diaphragm.

Step 3

Use a drift pin to align the center hole of the Fender Panel with the center hole of the Diaphragm.

Step 4

Step 5

Be sure Mushroom Washer lays flat against the Fender Panel as shown in Figure 63B. Standoff on Mushroom Washer must be seated completely through slot.

MUSHROOM WASHER

5/8” X 8 1/2”, G8 FLATHEAD SOCKET SCREW

BACKUP

FENDER PANEL

5/8” X 4” G5 HEX BOLT

6” DIE SPRING

5/8” RAIL NUT (LARGE)

5/8” LOCK WASHER

5/8” HEX NUT (SMALL)

LAST DIAPHRAGM

Figure 63

Wide Fender Panel Assembly

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LONG SLOT IN

FENDER PANEL

DIAPHRAGM OR BACKUP

5/8” RAIL NUT (LARGE)

6” DIE SPRING

MUSHROOM WASHER

QUAD-BEAM

FENDER PANEL

HINGE PLATE

PANEL ALREADY ATTACHED

TO DIAPHRAGM OR BACKUP

Mushroom Washer Attachment

Step 6

Check Diaphragm spacing to ensure 36” [915 mm] between rear faces of consecutive Diaphragms as shown in Figure 64 and Fender Panel Assembly drawing.

Step 7

Once the proper spacing has been achieved, tighten the Mushroom Washer Assembly (large rail nut) until it reaches the end of the threads. Assemble the remaining Diaphragms and Fender Panels following the same procedures. Tighten rail nut (large hex) at the front of the Fender Panels. Ensure the rail bolt shoulder is seated within the Fender Panel slot.

Figure 63A

Figure 63B

Mushroom Washer Orientation

Figure 64

Proper Diaphragm Spacing

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9) Attach End Cap

Using 5/8” x 3 1/2” G5 hex bolt, 5/8” hex nut and 5/8” lock washer, attach the End Cap to the front of the first Monorail segment.

Figure 65

Monorail End Cap Assembly

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10) Attach Cartridge Support Brackets

Attach Cartridge Support Bracket to all Diaphragms and Backup as shown in Figures 66 - 69, the Backup Assembly drawing, and the Diaphragm Assembly drawing.

DIAPHRAGM

CARTRIDGE

DIAPHRAGM

CARTRIDGE SUPPORT BRACKET

SUPPORT BRACKET

STEP II ATTACH “KEEPER”

Figure 66

Diaphragm with

Cartridge Support Bracket

STEP I ATTACH CARTRIDGE SUPPORT BRACKET

CARTRIDGE SUPPORT BRACKET

CONCRETE BACKUP

CARTRIDGE SUPPORT BRACKET IS WELDED TO THE FACE PLATE

FACE PLATE

Cartridge Support Bracket

Figure 67

Cartridge Support Bracket

(Tension Strut Backup)

Figure 68

(Concrete Backup)

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Extra-Wide First Diaphragm with Cartridge Support Bracket

11) Attach Nose Assembly

Figure 69

(See Drawing Package)

See pages 36 and 37 for Nose Assembly instructions.

12) Checking the System Assembly

Recheck to ensure that all fasteners are properly tightened throughout the system (anchor bolts, etc.). Review torque requirements below and inspect all Fender Panels. If they do not fit tightly against the underlying Fender Panels, system realignment may be necessary (Figure 70). Verify top of Steel Nose height is 32 1/8” above the roadway (p. 36).

Warning:

Anchor Studs – Anchoring Information Table, p. 16 May slightly protrude above nuts

Anchor Studs above nuts – p. 46, Figure 54 Fender Panel Gap Wide – 1.00” [25 mm] see below

UNDERLYING FENDER, TRANSITION,

EXTENTION OR SIDE PANEL

Anchor Requirements

Critical Clearances

MAXIMIM GAP = 1.00” [25 mm]

FENDER PANEL

Figure 70

Fender Panel Gap for Wide Systems

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13) Cartridge Placement

Ensure the Adjustable Cartridge Support in the Nose is attached correctly (p. 36). The top surface of the Nose Cartridge should be horizontal.

To complete the assembly of a QuadGuard

II, place the appropriate Cartridge in each Bay and Nose section of the system. Type I Cartridges are placed toward the front (Nose) of the system; Type II Cartridges are placed toward the rear (Backup) of the system (Figures 71 and

72). Ensure all Cartridges are pointed toward the front of the system per Cartridge direction

arrow.

Warning:

Placing the wrong Cartridge in the Nose or any Bay will result in system

performance that has not been crash tested pursuant to the NCHRP Report 350 criteria.

Figure 71

Cartridge Placement

Figure 72

Five Bay System

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QuadGuard® II Final Inspection Checklist

Date: __________________________________

Site Location: ___________________________

Inspector: ______________________________

Refer to the QuadGuard® II manual and/or drawing package.

 Minimum clearance of 30” behind rear Fender Panels for movement (p. 15)  Proper Transition Panel is used for the type of barrier (p. 24, 42)  Every borehole and slot in Backup and Monorail is utilized (p. 25, 27, 28, 45, 46,

47)

 Anchor stud(s) height is 1.5” or less above the pad (p. 27)  If no transition is used, narrow side panels are used with backup (p. 29, 48)  Monorail guides are attached to the Diaphragms with shims (p. 30, 49)  Mushroom Washer tabs lay flat within fender panel slots (p. 32, 51)  Mushroom Washer nuts are bottomed out to shank on Mushroom Washer bolt (p.

32, 52)

 Monorail End Cap Assembly in place (p. 33, 53)  Cartridges are level and the same height in each Bay (p. 39)  Nose Cartridge is level (p. 36)  Fender Panel gap is 7/8” or less for Narrow (parallel) systems (p. 38)  Fender Panel gap is 1” or less for Wide (flared) systems (p. 55)  Cartridge types are in order, correctly seated, and facing the front of the system

(p. 39, 56)

 Bolts and nuts are properly tightened throughout the system (p. 38, 55)  Anchor nuts are torqued to adhesive manufacture specification (p. 16)  System is clear of debris

Important:

complete to make certain that the instructions provided in this manual have been strictly followed.

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It is critical that you inspect this product after assembly is

Page 59

Maintenance and Repair

Inspection Frequency

Inspections are recommended as needed based upon volume of traffic and impact history. Visual Drive-By Inspections are recommended at least once a month. Walk-Up Inspections are recommended at least twice a year for QuadGuard

Visual Drive-By Inspection

1) Check to see if there is evidence of an impact. If so, a walk-up inspection will be necessary.

2) Check to see if the Cartridges appear to be off the Support Brackets. Any damaged Cartridges will need to be replaced.

Warning: See Cartridge placement instructions on pages 39 and 56.

3) Verify the Steel Nose is properly attached and at 32 1/8” above roadway surface.

4) Note the location and condition of the QuadGuard inspection.

Walk-Up Checklist

 Clear and dispose of any debris on the site.

II Narrow systems on asphalt (p. 16).

II and the date of visual drive-by

 Clear and remove excessive dirt from around the Monorail and Diaphragm feet.  Fasteners (nuts/bolts) are tight and rust free.  Anchor bolts are securely anchored.  Diaphragm legs are straight.  All Mushroom Washer Assemblies are properly seated.  Fender Panels and Transition Panels should nest tightly against the system.  Cartridges have not been damaged and are properly seated on their Support Brackets.

To ensure intended speed characteristics, partially crushed Cartridges (due to low speed impacts) must be replaced.

 Post-Impact Instructions (p. 59)  To determine if a product should be replaced or is potentially reusable, a trained engineer

experienced in highway products and directed by the DOT, or other appropriate local highway authority, must be consulted.

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Post-Impact Instructions

Important: It is the sole responsibility of the project engineer and/or the

local highway authority and its engineers to determine whether use or reuse of any part of the system is appropriate or acceptable following an impact. Trinity Highway makes no recommendation or suggestion regarding this determination. Each impact is unique.

Warning: If the QuadGuard

than 10% of the total anchors are damaged, then each damaged anchor must be replaced. If more than 10% of the anchors are damaged, then the system must receive a fresh, undisturbed asphalt foundation and be redeployed using

18” [460 mm] threaded rods.

Narrow (Parallel) Systems

1) Deploy the appropriate traffic-control devices for protection.

2) Check to see that all anchor bolts have remained firmly anchored in the roadway surface. Replace any that are loose, broken, or pulled out.

The proper performance of the system depends on the Monorail anchors being properly anchored.

3) Clear and dispose of any debris on the site.

4) Check the system to be certain that the Mushroom Washer Assemblies holding the Fender Panels together are still intact and that the system has not been deformed in a way that would prevent pulling it back to its original position.

II Narrow system is anchored to asphalt and less

5) Be sure that the Diaphragm Support Legs are all properly attached to the Monorail.

Wide (Flared) Systems

1) Deploy the appropriate traffic-control devices for protection.

2) Check to see that all anchor bolts have remained firmly anchored in the roadway surface. Replace any that are loose, broken, or pulled out.

Important: Performance of the system depends on the Monorail Anchors being

properly anchored.

Caution: QuadGuard

3) Clear and dispose of any on site debris.

5) Ensure that each Diaphragm is properly attached to the Monorail.

II wide systems should not be anchored to asphalt.

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Caution:

Assembly. Do not place fingers underneath an assembled Mushroom Washer. Parts may suddenly shift and fingers may be pinched. If the spring is still under compression as the nut is nearing the end of the bolt, to prevent injury, make sure that the spring is restrained with a clamp so it does not suddenly release when nut is removed from the Mushroom Washer Bolt.

6) Attach chain to Pullout Brackets on first Diaphragm (Figure 73). Attach both ends of chain to a heavy vehicle (such as a 1 ton pickup).

Use eye protection and gloves when refurbishing the Mushroom Spring

Warning:

Important:

original length. Have someone watch the system during repositioning to be certain previously undetected damage does not cause the Diaphragms to bind or pull out improperly.

Stand clear in case chain breaks or becomes disconnected.

Figure 73

Pullout

Slowly pull the QuadGuard® II forward until the system reaches its

7) Remove all crushed Cartridges from within the system.

8) Check to see that the Diaphragms are in usable condition. Diaphragms which are bowed or have bent legs must be replaced.

9) Check that the Fender Panels are properly attached with the Mushroom Washer Assemblies. Damaged Fender Panels and Transition Panels must be replaced

Warning:

Fender Panel Maximum gap allowed:

Narrow Systems 7/8” [22 mm] Wide Systems 1.00” [25 mm]

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10) Check the gaps between Fender Panels. The maximum gap allowed for these overlapping parts (including Fender Panels overlapping Panels behind the system) is

7/8” [22 mm] for narrow systems and 1.00” [25 mm] for wide systems. Be sure the

Mushroom Washer Assemblies are tightened to the end of the threads. If the gaps between the Fender Panels are still too large, it may be necessary to replace bent parts.

MAXIMUM GAP = 7/8” [22 mm]

UNDERLYING FENDER,

TRANSITION, EXTENTION

OR SIDE PANEL

Narrow Systems Fender Panel Gap

11) Replace all crushed Cartridges. See Cartridge Placement on pages 39 and 56.

12) Remove damaged Nose Assembly and attach the new Nose (p. 36 and 37).

Important: Trinity Highway makes no recommendation whether use or

FENDER PANEL

Figure 74

MAXIMUM GAP = 1.00” [25 mm]

UNDERLYING FENDER,

TRANSITION, EXTENTION

OR SIDE PANEL

FENDER PANEL

Figure 75

Wide Systems Fender Panel Gap

Warning:

Anchor Requirements

Anchor Studs – p. 16

Critical Clearances

Anchor Studs above nuts – Figure 54, p. 46

Fender Panel Gap Narrow – 7/8” [22 mm] Fender Panel Gap Wide – 1.00” [25 mm]

13) Verify all bolts on the system are tight (p. 16).

14) Ensure that the site is free from any debris.

15) The QuadGuard

II is now ready for use.

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Parts Ordering Procedure

Make a list of all damaged parts using part descriptions shown on the components pages 7 - 11 and on the system images (p. 63 and 64). Answer the following questions in the spaces provided. This information is necessary to receive the proper parts.

QuadGuard® II Ordering Information Chart

Description:

What is the width of the system (p. 21)?

24” [610 mm] 30” [760 mm] 36” [915 mm] 48” [1219 mm] 69” [1755 mm] 90” [2285 mm] 126” [3200 mm]

Choices Fill in this section

What is the Number / Type of Bays?

See Bay information on pages 39 and 56.

What Type of Backup Does the System Have? Figures 9 or 10 (p. 23).

What Type of Transition Panel?

Reference “Side Panel and Transition Panel Types” (pp. 24 and 42). Be sure to

specify right side, left side, or no Transition(s). See “How to Determine Left/Right” on page 20.

Narrow Systems: 1 through 5 Wide Systems: 3 through 6

Concrete Tension Strut

Quad to W Quad to Thrie Quad to Safety Shape Barrier Quad to End Shoe 4” Offset Panel

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CARTRIDGE

SUPPORT

BRACKETS

MONORAIL GUIDE

DIAPHRAGM

TYPE I CARTRIDGES

DIAPHRAGM

TYPE II CARTRIDGES

BACKUP

(CONCRETE SHOWN)

FIRST DIAPHRAGM

STEEL NOSE ASSEMBLY

APPROVED ADHESIVE

WITH 3/4” X 7” STUD

MONORAIL (UNDER SYSTEM)

APPROVED ADHESIVE KIT

MONORAIL SECTION

TRANSITION PANEL

(NUMEROUS TYPES)

QUAD-BEAM FENDER PANEL

MUSHROOM WASHER ASSEMBLY

Figure 76

QuadGuard

II for Narrow

Roadside Obstacles

5/8” HEX NUT

5/8” X 1 3/4”

FLAT WASHER

1 1/2” SPRING

MUSHROOM WASHER

5/8” X 5” FLAT SCREW

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CARTRIDGE

SUPPORT

BRACKETS

FIRST DIAPHRAGM

MONORAIL GUIDE

STEEL NOSE ASSEMBLY

DIAPHRAGM

TYPE I CARTRIDGES

TRANSITION PANEL

(NUMEROUS TYPES)

BACKUP

WITH 3/4” X 7” STUD

MONORAIL SECTION

HINGE

DIAPHRAGM

TYPE II CARTRIDGES

(CONCRETE SHOWN)

MONORAIL (UNDER SYSTEM)

APPROVED ADHESIVE KIT

5/8” RAIL NUT

6” DIE SPRING

MUSHROOM WASHER ASSEMBLY

APPROVED ADHESIVE

5/8” X 2” RAIL BOLT

QUAD-BEAM FENDER PANEL

MUSHROOM WASHER

5/8” X 8 1/2” FLAT SCREW

Figure 77

QuadGuard

II for Wider

Roadside Obstacles

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Notes:

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Notes:

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